Vertical shipment dunnage

ABSTRACT

The invention described herein generally pertains to dunnage apparatus for securing an object in a vertical orientation for shipment. The apparatus includes a carton having a cutout portion adapted to at least partially receive an object to be supported. The apparatus secures the object during a stretch wrap process which joins the apparatus and the object together as a unit.

CROSS REFERENCE TO RELATED APPLICATION(S)

This application claims the benefit of and priority to U.S. Provisional Application Ser. No. 62/448,636, filed on Jan. 20, 2017. The entirety of this application is incorporated herein by reference.

TECHNICAL FIELD

In general, the present invention relates to dunnage to facilitate shipping objects in a vertical orientation.

BACKGROUND OF THE INVENTION

Some products or objects are shipped as a pallet load. In preparation for shipment, a loaded pallet is stretched wrap to unitize the load with the pallet, to stabilize the load, and to protect the load for shipping. For objects shipped vertically, such that a long dimension of the object extends vertically upward from the pallet, load stability can be maintained with conventional stretch wrapping when the grouping of objects has a footprint exceeding a determined minimum. The International Safe Transit Association (ISTA) 3E testing procedures can be a useful tool to determine the minimum footprint. For groupings having less than the minimum footprint, additional, labor-intensive securing means are employed to maintain stability, such as using roped stretch wrap to tie down and support the objects.

SUMMARY OF THE INVENTION

A simplified summary is provided herein to help enable a basic or general understanding of various aspects of exemplary, non-limiting embodiments that follow in the more detailed descriptions and the accompanying drawings. This summary is not intended, however, as an extensive or exhaustive overview. Instead, the sole purpose of the summary is to present some concepts related to some exemplary non-limiting embodiments in a simplified form as a prelude to the more detailed description of the various embodiments that follow.

In accordance with an embodiment of the present invention, a dunnage apparatus is provided. The apparatus can include a carton having a top panel, a bottom panel, and a plurality of sidewalls extending therebetween. The apparatus further includes an opening formed in the carton. The opening can have a top edge formed in the top panel, a bottom edge formed in the bottom panel, and a side edge formed in at least two sidewalls. When deployed to secure an object vertically oriented for shipment, the top edge is configured to engage along at least a portion of a cross-sectional perimeter of the object, the side edge engages a vertical surface of the object, and the bottom edge forms a bottom support panel on which the object rests.

These and other objects of this invention will be evident when viewed in light of the drawings, detailed description and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may take physical form in certain parts and arrangements of parts, a preferred embodiment of which will be described in detail in the specification and illustrated in the accompanying drawings which form a part hereof, and wherein:

FIG. 1 illustrates an exemplary, non-limiting embodiment of a dunnage apparatus according to one aspect;

FIG. 2 illustrates an exemplary, non-limiting embodiment of a dunnage apparatus oriented in position to engage an object in accordance with one or more aspects;

FIG. 3 illustrates an exemplary, non-limiting embodiment of a pair of dunnage apparatuses securing an object;

FIG. 4 illustrates an exemplary, non-limiting embodiment of an object secured by one or more dunnage apparatuses to form an assembly that is arranged on a pallet;

FIG. 5 illustrates an exemplary, non-limiting embodiment of a plurality of objects jointly secured by one or more dunnage apparatuses in accordance with one or more aspects;

FIG. 6 illustrates an exemplary, non-limiting arrangement of an object, as secured by one or more dunnage apparatuses, on a pallet according to an aspect;

FIG. 7 illustrates an exemplary, non-limiting embodiment of a dunnage apparatus according to an aspect; and

FIG. 8 illustrates an exemplary, non-limiting embodiment of a dunnage apparatus according to an aspect.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the invention relate to an apparatus to secure and support one or more objects in a vertical orientation for shipment. The apparatus includes a carton having a cutout portion adapted to at least partially receive an object to be supported. According to an aspect, the apparatus secures the object during a stretch wrap process which joins the apparatus and the object together as a unit. The apparatus, particularly exposed edges of the cutout portion, are configured to provide stabilizing forces to surfaces of the object. Moreover, the cutout portion can define a panel for supporting a bottom surface of the object.

In accordance with one or more aspects, the carton can be a box foldable into a substantially rectangular prism, but having a cutout portion constituting approximately a quarter of the carton volume. The box can be formed from corrugated cardboard, for example, with the flute direction of the corrugated box arranged relative to the cutout portion so as to be orthogonal to the edges of the cutout. With this arrangement, the flute direction can also be orthogonal to one or more surfaces of the object to be secured and supported in a vertical orientation.

According to one exemplary, non-limiting embodiment, the apparatus can be deployed to secure a tall, slender object such as a 50 pound can that contains welding electrodes. In this example, the can have a substantially rectangular or square cross-section approximately five inches on a side. The height of the can range from approximately 12 inches to 18 inches. It is to be appreciated that the apparatus can be configured to secure other objects of various sizes in accordance with aspects disclosed herein.

The best mode for carrying out the invention will now be described for the purposes of illustrating the best mode known to the applicant at the time of the filing of this patent application. The examples and figures are illustrative only and not meant to limit the invention, which is measured by the scope and spirit of the claims.

Referring now to the drawings, wherein the showings are for the purpose of illustrating an exemplary embodiment of the invention only and not for the purpose of limiting the same, FIGS. 1-7 illustrate a dunnage apparatus for supporting and securing one or more objects vertically oriented for shipment. As used herein, “vertically oriented” or “vertical orientation” means arranged such that a long dimension of an object to be secured for shipment extends upward from a surface on which the object is placed.

Turning initially to FIG. 1, a dunnage apparatus 100 is depicted having an upper surface 102, a bottom surface 104, and a plurality of sidewalls 106 that extend between the upper surface 102 and the bottom surface 104. The dunnage apparatus 100 includes an opening or cutout portion 108 formed therein that is adapted to at least partially receive an object vertically oriented for shipment. According to an example, where the dunnage apparatus 100 has a substantially box-like shape as shown in FIG. 1, the cutout portion 108 can visually appear as though a portion of the upper surface 102, a portion of the bottom surface 104, and portions of at least two sidewalls 106 have been removed from the box-like shape.

As shown in FIG. 1, the cutout portion 108 includes edges 110, 112, 114 formed in the upper surface 102, bottom surface 104, and sidewalls 106 respectively. The edges 110, 112, 114 can be configured differently so as to support, stabilize, or grip the object in different manners. That is, the edges 110, 112, 114 can define differing contours in the surfaces in which the edges are respectively formed. For instance, as shown in the example apparatus of FIG. 1, the top edge 110 formed in the upper surface 102 can have a contour forming a right angle. The bottom edge 112 formed in the bottom surface 104 can have a contour corresponding to a line segment diagonally extending between the two side edges 114. The side edges 114 can have a straight contour extended between the top edge 110 and bottom edge 112.

Turning to FIG. 2, the dunnage apparatus 100 is oriented so as to readily receive an object 118 via the cutout portion 108. As shown in FIG. 2, the bottom edge 112 of the cutout portion 108 is shaped so as to provide a panel 116 on the bottom surface 104 of the apparatus 100. In FIG. 2, the general boundary of panel 116 on the bottom surface 104 is shown by the dashed line. The panel 116 can be slid under a bottom surface of object 118 when the apparatus 100 receives the object 118. Thus, the panel 116 provides a bottom support that cradles the object 118 to retain and support the object for a stretch wrap process. The panel 116, once secured beneath the object 118, additional operates to temporarily fix the apparatus 100 and object 118 together as a unit in an appropriate relative orientation until secured together via the stretch wrap process.

According to one aspect, the top edge 110 can be configured to grip partially around the object 118. For instance, as shown in FIG. 2, the contour of top edge 110 is configured to enable the top edge 110 to engage at least two surfaces of object 118. The top edge 110 can fully engage an entire width of the surface(s) or a portion thereof. As used in this example, “width” refers to a dimension of the object 118 extending substantially parallel to the edge 110. More generally, the contour of top edge 110 is designed to correspond to an outer dimension or perimeter of object 118. For example, the contour can be substantially matched in shape to at least a portion of a cross-sectional perimeter of the object 118. Thus, while FIGS. 1-7 illustrate a right-angled contour for top edge 118 adapted to partially engage objects having rectangular cross-sections, it is to be appreciated that the contour can be an arc to engage curved object surfaces or include one or more segments joined at various angles to engage other polygonal shapes (e.g., triangular, rectangular, pentagonal, hexagonal, octagonal, etc.).

The side edges 114 are configured to extend in a direction corresponding to the vertical dimension of the surfaces of object 118. Accordingly, the side edges 114 provide a stabilizing force to the surfaces of the object 118 to facilitate maintaining the object 118 in the vertical orientation.

Turning to FIG. 3, illustrated is an exemplary, non-limiting deployment of a pair of dunnage apparatuses 100 to stabilize and secure an object 118. As shown, the pair of apparatuses 100 substantially engage the perimeter of object 118 to secure the object 118 in the vertical orientation. Respective panels 116 of the pair of apparatuses 100 jointly provide a platform substantially supporting an entirety of the bottom surface of object 118. Accordingly, the pair of apparatuses 100 and object 118 are temporarily fixed to a degree sufficient to maintain the arrangement during a stretch wrap process. As shown in FIG. 4, the unit constituted by the pair of apparatuses 100 and the object 118 can be positioned on a pallet 120. The unit (formed by apparatuses 100 and object 118) and the pallet 120 will be unitized by the stretch wrap process.

FIG. 5 depicts a pair of dunnage apparatuses 100 deployed to secure two objects 118 on pallet 120. As shown, the two objects 118 are placed side-by-side to form a grouping of objects 118. The pair of dunnage apparatuses 100 engage the grouping of objects 118 at opposing corners. In one example, each apparatus 100 respectively engages an individual object 118. The objects 118 can additionally support and stabilize one another via the contacting surfaces thereof. Further, each object 118 is supported and stabilized by the respective apparatus 100 as described above and shown in FIG. 5. As such, the entire unit is sufficiently stabilized to withstand an automated stretch wrap process to secure the unit and pallet 120 together for shipping. Thus, according to this embodiment, a similar pair of dunnage apparatuses 100 employed to secure a single object can also be utilized to secure multiple objects.

In another example, the dunnage apparatuses 100 can be specifically configured for multiple objects so that each dunnage apparatus 100 engages both objects 118. For instance, the dunnage apparatuses 100 can wrap around the perimeter of objects 118 such that at least one section of the apparatuses 100 extends past a contact plane between the objects 118 themselves. Still further, depending on relative sizes between the dunnage apparatuses 100, objects 118, and pallet 120, each object 118 can be respectively secured via a pair of dunnage apparatuses 100 as shown in FIG. 4 to form respective units. The units can be individually arranged on the pallet 120 prior to stretch wrapping. For instance, the individual units can be placed in a tiling arrangement and, in some exemplary arrangements, placed to eliminate gaps therebetween.

According to another aspect, FIG. 6 illustrates an arrangement of an object-dunnage assembly on a pallet 120. The assembly includes at least one object 118 and one more dunnage apparatuses 100. The assembly has a long dimension having a length L_(A) and the pallet 120 has a long dimension having a length L_(P). The assembly is arranged on the pallet 120 so as to orient the long dimension of the assembly to align substantially parallel to the long dimension of the pallet 120. When the long dimensions align, the assembly and pallet unit is further stabilized for stretch wrapping.

FIG. 7 depicts an exemplary, non-limiting dunnage apparatus according to one or more aspects. The apparatus 100 can include one or more dimensions including at least a height H, a full width W, and a cutout width C. The following guidelines can be considered when establishing these dimensions for a dunnage apparatus 100. It is to be appreciated that these guidelines are merely illustrative of a possible configuration for the dunnage apparatus 100 and that the dunnage apparatus claimed herein is not limited to the particular dimensions set forth in this example. The height of apparatus 100 can be established relative to the object 118 being secured. For instance, the height of apparatus 100 can be approximately 50% or more of the height of the object 118. In general, the full width W of apparatus 100 should be dimensioned to sufficiently accommodate the chosen cutout width C without structurally compromising the apparatus 100. According to one example, approximately a 2:1 ratio between the width W and cutout width C can be maintained.

For the cutout width C, a length can be considered which corresponds to a width of the object surface to be supported. The cutout width C can correspond identically with the width of the object surface or be substantially the width of the object surface (e.g., greater than half). According to another example, the apparatus 100 can have differing edge lengths along the cutout portion. For instance, cutout width C₁ can be greater than or less than cutout width C₂. In this example, one portion of the dunnage apparatus 100 can extend beyond the width of the object when deployed. The extension can abut a second dunnage apparatus 100 also deployed to secure the object. In particular, the extension created when C₁ and C₂ can provide the at least one section of the dunnage apparatus configured to extend past the contact plane of two objects 118 as described above in connection with FIG. 5.

FIG. 8 an exemplary, non-limiting embodiment of a dunnage apparatus according to an aspect. As shown, the dunnage apparatus 100 can be a collapsible piece of material that can be folded into a carton. The foldable carton can include corrugate box features (e.g., tabs, slots, flaps, etc.) to enable interlocking of various faces. Further, the foldable carton can include auto-bottom features to enable formation of various surfaces without the use of adhesives (i.e. glue, tape, etc.).

In accordance with the foregoing, in one embodiment, a dunnage apparatus is provides that includes a carton having a top panel, a bottom panel, and a plurality of sidewalls extending therebetween. The dunnage apparatus also includes an opening formed in the carton having a top edge formed in the top panel, a bottom edge formed in the bottom panel, and respective side edge formed in at least two sidewalls. When the dunnage apparatus is deployed to secure an object vertically oriented for shipment, the top edge is configured to engage along at least a portion of a perimeter of the object, the side edges respectively engage vertical surfaces of the object, and the bottom edge forms a bottom support panel on which the object rests.

In one example, the dunnage apparatus is deployed with a second dunnage apparatus to secure the object. The top edge of the opening can have a shape corresponding to a shape of the portion of the perimeter of the object. In some examples, the top edge can include a first segment and a second segment arranged perpendicularly to one another. The first segment can have a greater length than the second segment. When deployed, the first segment engages surfaces of two or more objects.

In addition, the carton can be foldable such that the carton can transition from a collapsed initial state into a final state for deployment. In yet another example, the carton can be a rectangular prism and the opening is formed at a vertical edge of the prism between a pair of sidewalls. The carton can be formed of a corrugated material such that a direction of the corrugates are perpendicular to surfaces of the object at points of engagement.

According to another aspect, an apparatus is described. The apparatus includes a box having an interior volume defined by an upper surface, a bottom surface, and a plurality of side surfaces extending between the upper surface and the bottom surface. The apparatus also includes an opening to expose the interior volume of the box for partially receiving an object therein. The opening is delineated by a first contour in the upper surface, a second contour in the bottom surface, a third contour in a first side surface, and a fourth contour in a second side surface. When the apparatus is deployed to secure the object in a vertical orientation for shipment, the object engages one of more delineations of the opening formed in the surfaces of the box. The apparatus can be deployed with a second apparatus to secure the object.

In one or more examples, the first contour is configured to engage around at least a portion of an outer perimeter of the object. For instance, the first contour corresponds to at least a portion of a cross-sectional shape of the object. The second contour forms a support panel on which the object rests when partially received within the interior volume of the box. The third contour and the fourth contour provide respective edges in the first and second side surfaces that respectively engage at least one surface of the object. In one aspect, the opening defines a negative volume in the box that matches at least a portion of a shape of the object.

In yet another embodiment, a dunnage apparatus is described that includes a foldable carton of corrugated material that, when folded, includes a top panel, a bottom panel, a plurality of sidewalls extending therebetween, and an opening that exposes an interior volume of the carton. The opening is delineated by a top edge formed in the top panel of the carton, a bottom edge formed in the bottom panel of the carton, and a pair of side edges formed in respective sidewalls of the carton. To secure an object in a vertical orientation, the top and sides edges of the opening are configured to engage respective surfaces of the object and the bottom edge forms a surface configured to support a bottom of the object, thereby partially receiving the object into the interior volume of the carton.

A flute direction of the corrugation along the top edge and the side edges of the opening are perpendicular to respective surfaces of the object. The top edge has a contour that corresponds to at least a portion of a cross-section shape of the object to enable the carton to partially wrap around the object when deployed. When deployed, the dunnage apparatus secures with the object as unit for stretch wrapping. According to an example, a height of the carton is at least one half a height of the object.

The above examples are merely illustrative of several possible embodiments of various aspects of the present invention, wherein equivalent alterations and/or modifications will occur to others skilled in the art upon reading and understanding this specification and the annexed drawings. In particular regard to the various functions performed by the above described components (assemblies, devices, systems, and the like), the terms (including a reference to a “means”) used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function of the described component (e.g., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the illustrated implementations of the invention. In addition although a particular feature of the invention may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Also, to the extent that the terms “including”, “includes”, “having”, “has”, “with”, or variants thereof are used in the detailed description and/or in the claims, such terms are intended to be inclusive in a manner similar to the term “comprising.”

This written description uses examples to disclose the invention, including the best mode, and also to enable one of ordinary skill in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that are not different from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

The best mode for carrying out the invention has been described for purposes of illustrating the best mode known to the applicant at the time. The examples are illustrative only and not meant to limit the invention, as measured by the scope and merit of the claims. The invention has been described with reference to preferred and alternate embodiments. Obviously, modifications and alterations will occur to others upon the reading and understanding of the specification. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof. 

What is claimed is:
 1. A dunnage apparatus, comprising: a carton having a top panel, a bottom panel, and a plurality of sidewalls extending therebetween; an opening formed in the carton having a top edge formed in the top panel, a bottom edge formed in the bottom panel, and respective side edge formed in at least two sidewalls, wherein, when deployed to secure an object vertically oriented for shipment, the top edge is configured to engage along at least a portion of a perimeter of the object, the side edges respectively engage vertical surfaces of the object, and the bottom edge forms a bottom support panel on which the object rests.
 2. The dunnage apparatus of claim 1, wherein the dunnage apparatus is deployed with a second dunnage apparatus to secure the object.
 3. The dunnage apparatus of claim 1, wherein the top edge of the opening has a shape corresponding to a shape of the portion of the perimeter of the object.
 4. The dunnage apparatus of claim 1, wherein the carton is foldable, from a collapsed initial state, into a final state for deployment.
 5. The dunnage apparatus of claim 1, wherein the carton is a rectangular prism and the opening is formed at a vertical edge of the prism between a pair of sidewalls.
 6. The dunnage apparatus of claim 1, wherein the top edge includes a first segment and a second segment arranged perpendicularly to one another.
 7. The dunnage apparatus of claim 6, wherein the first segment has a greater length than the second segment.
 8. The dunnage apparatus of claim 7, wherein, when deployed, the first segment engages surfaces of two or more objects.
 9. The dunnage apparatus of claim 1, wherein the carton is a corrugated material and a direction of the corrugates are perpendicular to surfaces of the object at points of engagement.
 10. An apparatus, comprising: a box having an interior volume defined by an upper surface, a bottom surface, and a plurality of side surfaces extending between the upper surface and the bottom surface; and an opening to expose the interior volume of the box for partially receiving an object therein, the opening is delineated by a first contour in the upper surface, a second contour in the bottom surface, a third contour in a first side surface, and a fourth contour in a second side surface, wherein, when deployed to secure the object in a vertical orientation for shipment, the object engages one of more delineations of the opening formed in the surfaces of the box.
 11. The apparatus of claim 10, wherein the first contour is configured to engage around at least a portion of an outer perimeter of the object.
 12. The apparatus of claim 10, wherein the first contour corresponds to at least a portion of a cross-sectional shape of the object.
 13. The apparatus of claim 10, wherein the second contour forms a support panel on which the object rests when partially received within the interior volume of the box.
 14. The apparatus of claim 10, wherein the third contour and the fourth contour provide respective edges in the first and second side surfaces that respectively engage at least one surface of the object.
 15. The apparatus of claim 10, wherein the opening defines a negative volume in the box that matches at least a portion of a shape of the object.
 16. A dunnage apparatus, comprising: a foldable carton of corrugated material that, when folded, includes a top panel, a bottom panel, a plurality of sidewalls extending therebetween, and an opening that exposes an interior volume of the carton, wherein the opening is delineated by a top edge formed in the top panel of the carton, a bottom edge formed in the bottom panel of the carton, and a pair of side edges formed in respective sidewalls of the carton, and wherein, to secure an object in a vertical orientation, the top and sides edges of the opening are configured to engage respective surfaces of the object and the bottom edge forms a surface configured to support a bottom of the object, thereby partially receiving the object into the interior volume of the carton.
 17. The dunnage apparatus of claim 16, wherein a flute direction along the top edge and the side edges of the opening are perpendicular to respective surfaces of the object.
 18. The dunnage apparatus of claim 16, wherein the top edge has a contour that corresponds to at least a portion of a cross-section shape of the object to enable the carton to partially wrap around the object when deployed.
 19. The dunnage apparatus of claim 16, wherein, when deployed, the dunnage apparatus secures with the object as unit for stretch wrapping.
 20. The dunnage apparatus of claim 16, wherein a height of the carton is at least one half a height of the object. 